Transcript
SmartZonePLUS
TM
System Manual
This document applies to the following product models and versions: SmartZonePLUS™ EC1 – Equipment Controller - hardware v1.3, firmware r1, r2 SmartZonePLUS™ RZ1 – Remote Zone 1 Controller - hardware v1.3, firmware r1 SmartZonePLUS™ RZ4 – Remote Zone 4 Controller - hardware v1.3, firmware r1
XCI Controls Technical Support: 866-XCI-CTRL (866-924-2875)
™
SmartZonePLUS System Manual Table of Contents SmartZonePLUS™ Feature Overview Figure 1.1
EC1 Controller
Figure 1.2
RZ1 Zone Expander (1 zone)
Figure 1.3
RZ4 Zone Expander (4 zones)
Section 1: PrePre-installation……………………………………………… p. 8 1.1
Most Common Mistakes Wiring Undersized Transformer Thermostat Configuration
1.2
Other Considerations Thermostat Selection Supply Air Damper Selection Fresh Air Ventilation Option Balance Point Heat Pump Control Option
Section 2: Installation…………………………………………………… p. 10 2.1
Supply Air Temperature Sensor
2.2
Mounting SmartZonePLUS™ EC1 Controller and RZ1/RZ4 Expanders
2.3
Power & Power Wiring Using a single transformer Using multiple transformers
2.4
Communication Wiring
2.5
Thermostats and Thermostat Wiring EC1 Controller Thermostat Wiring RZ1 and RZ4 Expander Thermostat Wiring
2.6
Supply Air Bypass Duct and Damper
2.7
Zone Damper Wiring Power Close/Spring Open (two-wire) Dampers Power Open/Power Close (three-wire) Dampers
2.8
Fresh Air Damper Wiring (optional)
2.9
Power On Test
2.10
Configuration
2.11
HVAC Equipment Wiring
2.12
Optional Configuration Settings
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 2
High and Low Temp Cutout Fresh Air Timer Humidity Control Multi-speed Fan Economy Mode Opposing Heat and Cool Calls HVAC Equipment Staging
Section 3: Control Functions…………………………………………… p. 25 3.1
Staging Control
3.2
Heat Pump Reversing Valve Control
3.3
Heat Pump Balance Points
3.4
Opposing Heating and Cooling Calls Dynamic Opposing Call Management Fixed Time Opposing Call Management
3.5
Emergency Heat Call – Heat Pumps
Section Section 4: Operation & Monitoring …………………………………… p. 28 4.1
Using the Display Panel
4.2
Damper LED Indicators
Appendices:… Appendices:………………………………………………………………… ……………………………………………………………… p. 34 A
EC1 Controller Dipswitch Settings
B
Transformer and Fuse Sizing Worksheet
C
Duct Sizing
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 3
SmartZonePLUS™ Feature Overview SmartZonePLUS™ Expandable Zoning System is a highly flexible and reliable zoning control product with superior features and functionality for the residential and light commercial HVAC zoning markets. Expandable from 2 to 33 zones, SmartZonePLUS™ requires a single zone EC1 Controller plus additional zones that can be added in any combination using the RZ1 (single zone expansion module) and/or RZ4 (four zone expansion module). SmartZonePLUS™ will work with nearly any domestic major brand HVAC equipment in split or packaged system configurations for gas/electric, heat pump and dual fuel applications. HVAC contractors benefit from time saving installation features such as push wire connectors and color coded LED’s that simplify system configuration, diagnostics and monitoring.
General Features:
Expandable from 2 – 33 zones for residential or light commercial applications
Compatible with major domestic HVAC brands – single stage or two stage capacity
Flexible configuration works with gas/electric, heat pump and dual fuel
Comfort/Economy mode at thermostat terminals, individual zone or global configuration
Configurable temperature staging control – two cooling and three heating stages
Adjustable control settings: •
Heat pump balance point control – Outdoor low temp compressor cutout/high temp aux heat cutout
•
High/Low temp furnace/compressor cutout
•
High/Low temp fresh air ventilation cutout with adjustable run timer
Short-cycle compressor protection
Full function status display panel
Color-coded LED indicators display active calls from each thermostat, outputs to equipment and zone damper status
Push-wire thermostat, damper and equipment connectors save installation time
Automatic opposing call management with configurable fixed time changeover feature
Multi-speed fan control
Configurable for mixed use of heat pump and gas/electric thermostats
Zone 1 humidify or dehumidify control using a humidistat
Included supply air temperature sensor; optional outdoor air temperature sensor
5 year limited warranty
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 4
RC RH jumper for separating heating and cooling transformers Display panel
24V power connector from equipment
24V equipment connectors
Push buttons for display panel and changing control se
Reset button for technical support and future features
Zone 1 thermostat wiring connector
Color coded LED indicators for thermostat, dampers, communications and equipment
Jumper or connector for all zone economy mode setting Supply air sensor connector
Outdoor air sensor connector
Fresh air damper connector Dipswitch panel
RS485 Communication wiring connector – (for future use)
Zone 1 supply air damper wiring connector
Communication wiring connector to RZ1 or RZ4
24V power in wiring connector from transformer
24V power out wiring connector to RZ1 or RZ4
Figure 1.1: SmartZonePLUS™ EC1 Controller
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 5
Display panel
24V power in wiring connector from EC 1, RZ1 or RZ4
Permanent jumper for RZ1 zone economy mode setting
Push button for selecting thermostat type
Communication wiring connector from EC1,RZ1 or RZ4 expander
Color coded LED indicators for thermostat, dampers and communications
24V power out wiring connector to RZ1 or RZ4
Reset button for technical support and future features
Communication wiring connector to RZ1 or RZ4 expander
Thermostat wiring connector
Supply air damper wiring connector
Figure 1.2: SmartZonePLUS™ RZ1 Zone Expander
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 6
Display panel
24V power in wiring connector from EC 1, RZ1 or RZ4
Push button for selecting thermostat type
Permanent jumper for RZ4 zone economy mode setting Communication wiring connector from EC1,RZ1 or RZ4 expander
Color coded LED indicators for thermostat, dampers and communications
24V power out wiring connector to RZ1 or RZ4
Communication wiring connector to RZ1 or RZ4 expander
Reset button for technical support and future features
Thermostat wiring connectors Supply air damper wiring connectors for zones 1,2,3,4
Figure 1.3: SmartZonePLUS™ RZ4 Zone Expander
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 7
Section 1: Pre-installation 1.1 Most Common Mistakes Installer errors represent the highest percent of installation problems based on calls to our technical support department. A few minutes devoted to understanding the installation process and requirements will save you time and money in the initial installation and will help reduce the chance of call backs. Wiring – The most common cause of problems result from wiring mistakes.
Wiring issues
typically are caused by not adhering to the correct wiring specifications or poor wiring connections and connecting wire leads to the wrong connectors. For detailed information refer
to Section 2: Installation. Warning!!
Always disconnect power to all SmartZonePLUS™ components when connecting wiring to a SmartZonePLUS™ board, damper, thermostat or any other connected device.
Undersized Transformer – SmartZonePLUS™ electronics use processor chips with specialized software to manage their functions. Proper function depends on an adequate and stable level of power. Using a dedicated transformer or transformers sized to the scale of zone operation, SmartZonePLUS™ will be supporting is critical to insure reliable and proper performance. More zones require more thermostats which require more expansion boards which require more
Use the Transformer and Fuse Sizing Worksheet in Appendix B to insure you have determined the proper transformer and fuse sizes needed. dampers which require more power.
Thermostat Configuration Configuration – SmartZonePLUS™ requires the installer to configure the EC1 Controller and RZ Expander boards. In heat pump installations it is possible to mix heat pump and gas/electric thermostats. Failure to correctly configure each SmartZonePLUS™ board for the thermostat types (gas/electric or heat pump) used can result in erratic and unpredictable equipment performance. Review Section 2: Configuration – Step 1 Thermostat Type.
1.2 Other Considerations Thermostat Selection - SmartZonePLUS™ allows considerable flexibility and opportunity to reduce costs or satisfy individual requirements with the type of thermostats used. SmartZonePLUS™ will allow single stage gas/electric thermostats to be used with multistage heat pump HVAC equipment. Thermostat types can be mixed in a single system with multiple RZ Expander boards but the same type must be used on any single RZ4 board. For example, on a heat pump system with 9 zones (1 EC1 and 2 RZ4 expanders) one RZ4 Expander may use heat pump thermostats and the second RZ4 Expander may use all gas/electric thermostats. Zone 1 on the EC1 Controller is the only zone thermostat connector with wire connections for second stage heating/cooling (W2/Y2), humidify/dehumidify (H) and emergency heat (EH). Select a multistage thermostat for Zone 1 if it is necessary to override the SmartZonePLUS™ staging controls.
XCI Controls, L.P.
SmartZonePLUS™ protection controls for high/low temp and compressor
December 19, 2008
P/N 220211-02
pg. 8
short cycling will continue to function. Although a gas/electric thermostat can be used, heat pump systems with emergency heat will require a heat pump thermostat, connected to the EC1 board only, to MANUALLY control emergency heat from the thermostat. Refer to Section 3.5:
Emergency Heat Call – Heat Pumps. The humidify/dehumidify feature requires the EC1 Controller “Thermostat 1” to use a
Refer to Section 2.12 Optional Configuration Settings - Humidity Control for further information. thermostat that can make humidification or dehumidification calls.
Warning!!!
SmartZonePLUS™ does not support power stealing or battery backback-up thermostats although some may work. Supported thermostats must have a 24V power and 24V common terminal or thermostats that are truly battery operated. operated.
Fresh Air Ventilation Option – The EC1 Controller includes a fresh air damper power connector with an adjustable timer to allow fresh air into the air supply. If fresh air ventilation is required the contractor will need to consider the additional ductwork, damper, fresh air duct sizing, wiring, 24V power requirements and other necessary supplies to use this feature. Refer to
Section 2.12: Optional Configuration Settings - Fresh Air Timer for further information. Balance Point Heat Pump Control Option – This feature works only with heat pump equipment and also requires an optional outdoor temperature sensor.
Refer to Section 3.3 Heat Pump
Balance Point Control for further information. Supply Air Dampers – SmartZonePLUS™ operates using two and/or three wire dampers. Two wire dampers generally use a spring mechanism to open the damper and an electronic actuator to close the damper.
The two wire (or “spring open/power close”) damper will require
approximately 10VA each compared with 3VA for the electronic actuators (“power open/power close”). A maximum of 13 three-wire dampers or four two-wire dampers can be connected to any single SmartZonePLUS™ zone connector.
The power requirements and quantity of each
damper type must be included in the total power requirements when sizing the transformer(s) needed to power SmartZonePLUS™ and its peripheral components. Multiple dampers powered from a single zone damper connector must be wired in parallel. Daisy-chain the ‘PC’ zone terminals to the corresponding connector for each damper to be powered off that zone terminal. Follow the same wiring scheme connecting ‘PO’ (if using 3-wire damper) and ‘COM’ damper connectors to the zone connector.
Refer to Section 2.3 Power & Power Wiring for further information.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 9
Section 2: Installation 2.1 Supply Air Temperature Sensor Each SmartZonePLUS™ EC1 Controller comes packaged with a supply air sensor. The supply air sensor is critical to the function of SmartZonePLUS™ controls that protect the HVAC equipment and control staging. The sensor has a 10’ lead with a green connector that plugs onto the EC1 Controller. Installation location of the sensor will vary between gas/electric, heat pump and dual fuel systems. Warning!!!
If the supply air sensor wire lead length is insufficient do not cut or splice wire into the existing lead as that may change change the performance of the sensor. An optional supply air sensor with a 50’ wire lead length is available if required. If splicing is unavoidable use 18AWG wire with a high quality splicing connection such as soldering.
Supply Air Sensor Sensor Installation – Gas/Electric Gas/Electric - The sensor should be located in the supply air plenum where it will sense average air temperature within the plenum. Ideal placement for the sensor will be 2 – 4 feet beyond the evaporator. Make sure the sensor is in the air stream and secured properly.
Sensor location
Figure 2.10 - Supply Air Sensor Installation – Gas/Electric Supply Air Sensor Installation – Heat Pump - The sensor is placed inside the cabinet of the air handler after the coil but before the blower. Make sure the sensor is in the air stream and secured properly.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 10
Sensor location
Figure 2.11 - Supply Air Sensor Installation – Heat Pump Supply Air Sensor Installation – Dual Fuel - The sensor should be located the same as gas/electric as illustrated in Figure 2.10. In a dual fuel application the furnace is never allowed to operate when the compressor is operating, thus AUX/EH is always fossil fuel only.
2.2 Mounting SmartZonePLUS™ EC1 Controller and RZ1/RZ4 RZ1/RZ4 Expansion Boards Important Note: The EC1 EC1 Controller comes with a supply air temperature sensor with a 10’ attached ttached plug connects to electrical lead. The sensor mounts in the supply air plenum and the a the EC1. EC1.
Make sure sure the EC EC1 mounting location is within reach of the supply air sensor
connector plug. 1. Remove the clear lid from the EC1 plastic enclosure and breakout the necessary “knockouts” for wiring on the side of the gray base or route wiring through the existing holes in the back of the enclosure. 2. Attach the gray base of the enclosure to a flat surface using at least 2 flat or pan-head screws. If mounting to a damper use optional din rail bracket. 3. Repeat step 1 & 2 for each SmartZonePLUS RZ1 and/or RZ4 expander boards. The RZ1 and RZ4 expander boards can be up to 4,000 feet away from the EC1 controller. Warning!!!
All SmartZonePLUS™ boards must be installed where temperatures are between 20º 20ºF and 160º 160ºF. Humidity must be less than 90% with NO direct moisture.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 11
2.3 Power & Power Wiring Note:
XCI Controls requires requires a dedicated 24VAC fused transformer for powering the
SmartZonePLUS™ controller and expansion boards. Multiple transformers may be used where convenience convenience or other factors dictate. When multiple transformers are used polarity must be maintained when connected to individual boards or if wired in parallel parallel.. Warning!!! •
Determine the VA rating of the transformer(s) needed to power all
Refer to Transformer Appendix B: Trans former and Fuse Sizing Worksheet for assistance in transformer(s).. sizing the transformer(s) SmartZonePLUS™ components before completing this step.
•
Do not connect line power to the transformers until all SmartZonePLUS™ power wiring is completed and checked!
Maintain polarity on both
primary and secondary sides of each transformer. transformer.
Always fuse and
ground each transformer. transformer. Connecting Power to the EC1 Controller 1. Review the Transformer and Fuse Sizing tables for each transformer used. (Appendix B). 2. Using 2 conductor 18AWG solid core wire, connect 24VAC and 24VAC(c) from the transformer to the 24V and 24C connections respectively on the PWR(In) connector located in the bottom left corner of the EC1 Controller. (Refer to Figure 2.30) a. strip ¾” of insulation off both ends of each wire conductor b. wire nut one end of each conductor to the transformer 24V and 24V(c) leads. c. insert the 24VAC conductor into the SmartZonePLUS™ PWR(In) 24V connector and the 24VAC(c) conductor into the 24C connector. Each conductor should be firmly secured in the connector with the copper wire shown slightly outside of the connector. This allows the technician to touch the wire with a volt meter if necessary. Connecting Power to the RZ1 and RZ4 Expansion Boards OPTION 1: Using a single transformer This option is practical for SmartZonePLUS™ installations where the EC1 Controller and RZ1/RZ4 expander modules are mounted in the same location and the power requirements are within the VA rating of a single transformer. Complete the Transformer and Fuse Sizing
Worksheet in Appendix B to determine the VA rating for the transformers used. a. Using 2 conductor 18AWG solid core wire, connect the EC1 Controller PWR(Out) connector to the RZ1 or RZ4 expansion board PWR(In) connector, Connect 24V to 24V and 24C to 24C. Strip ¾” of insulation from the end of each lead and firmly press the stripped wire end into the connector with the copper wire shown slightly outside of the connector. This allows the technician to touch the wire with a volt meter if necessary. If additional RZ1 and RZ4 expansion boards are used, connect the PWR(Out) connector from the previously connected RZ1/RZ4 expansion board to the PWR(In) connector on the next expansion board based on the sizing limit.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 12
Figure 2.30 – Single Transformer – EC1 and RZ1/4 OPTION 2: Using multiple transformers transformers Using
multiple transformers may be more
cost effective when
SmartZonePLUS™
installations involve mounting the EC1 Controller and RZ1/RZ4 expander modules in a distributed configuration across a large facility or multiple buildings. The transformer VA
rating for each mounting location will need to be determined using the Transformer and Fuse Sizing Worksheet in Appendix B. a. Using 2 conductor 18AWG solid core wire, connect 24V from the transformer to 24V and 24C to 24C on the RZ4/1 PWR(IN) terminal connector. Strip ¾” of insulation from the end of each lead and firmly press the stripped wire end into the connector with the copper wire shown slightly outside of the connector. touch the wire with a volt meter if necessary.
This allows the technician to
If additional RZ1 and RZ4 expansion
boards are used, connect the PWR(OUT) connector from the previously connected RZ1/RZ4 expansion board to the PWR(IN) connector on the next expansion board.
Figure 2.31 – Multiple Transformers – EC1 and RZ1 and/or RZ4 XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 13
2.4 Communication Wiring Warning!!!
To
avoid
damaging
SmartZonePLUS™
do
not
connect
line
power
to
SmartZonePLUS™ until all communication wiring is completed and checked. checked. 1. Using CAT5 or CAT5e wiring cable for all SmartZonePLUS™ communication wiring, connect the EC1 Controller COMM terminal block connectors “1”, “2”, and “GND” to the same connectors on the COMM(IN) terminal block on the nearest RZ1 or RZ4 Expander board. 2. Connect the “1”, “2”, and “GND” connectors on the COMM(OUT) terminal block on the RZ1 or RZ4 in step 1 above to the same connectors on the next RZ1 or RZ4 Expander board COMM(IN) terminal block. 3. Continue connecting the COMM(OUT) to COMM(IN) terminal blocks on remaining RZ1 and RZ4 Expander boards until all are connected.
Figure 2.40 – Communications Wiring Diagram
2.5 2.5 Thermostats and Thermostat Wiring Important Important Note: Read Thermostat Selection in Section 1.2 before proceeding. SmartZonePLUS™ requires use of thermostats that have a common terminal connection or are battery operated.
Follow the steps below to connect thermostats to each of the
SmartZonePLUS™ boards. Warning!!!
To
avoid
damaging
SmartZonePLUS™
disconnect
24V
power
to
SmartZonePLUS™ until all wiring connections are completed and checked.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 14
EC1 Controller Thermostat Wiring 1. Connect a heat pump or gas/electric thermostat to the terminal block labeled ZONE 1 THERMOSTAT. 2. If staging is to be controlled by the thermostat in addition to SmartZonePLUS™, use a multistage thermostat on Zone 1.
If SmartZonePLUS™ Electronic Limit Control
(ELC) will control staging then a single stage thermostat can be used. 3. Using 18AWG solid core wire, connect the applicable thermostat connectors corresponding
to
the
THERMOSTAT
ZONE1
terminals
labeled
R,C,Y1,Y2,G,W1/EH,W2/OB,H/G2 by holding down the orange button adjacent to the terminal openings and push the thermostat wires into the screwless terminals.
Figure 2.50 – Gas/Electric Thermostat Wiring for EC1 Controller
Figure 2.51 – Heat Pump Thermostat Wiring for EC1 Controller
RZ1 and RZ4 Expander Thermostat Thermostat Wiring The SmartZonePLUS™ RZ Expander boards are used to add zones in one or four zone increments up to a maximum of 33 zones including the zone on the EC1 Controller. Thermostat terminals on the RZ Expander boards do not have wiring connections for 2nd stage heat and cool so single stage thermostats are recommended. 1. Connect a heat pump or gas/electric thermostat to each thermostat terminal block as necessary based on the total of number of zones needed. 2. Using 18AWG solid core wire, connect the applicable thermostat connectors corresponding to the THERMOSTAT ZONE1 terminals labeled R,C,Y,G,W, H by holding down the orange button adjacent to the terminal openings and push the thermostat wires into the screwless terminals. 3. For multistage thermostats, connect only the 1st stage heating (W) and cooling (Y) on the thermostat.
The 2nd stage heating and cooling circuits (W2 & Y2) from the
thermostat will not be used.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 15
Figure 2.50 – Gas/Electric Thermostat Wiring for RZ1/RZ4 Expander
Figure 2.51 – Heat Pump Thermostat Wiring for RZ1/RZ4 Expander
2.6 Supply Air Bypass Duct and Damper Residential and light commercial HVAC systems typically rely on a fixed volume of airflow over the evaporator coil or heat exchanger to maintain proper function.
SmartZonePLUS™
recommends installation of a bypass duct and damper system to modulate or compensate for changes in airflow volume as dampers open and close supply air ducts to different zones. Sizing the bypass duct and calibrating the damper is a critical step in insuring optimal operation of SmartZonePLUS™ and the HVAC equipment. Install a damper in the bypass duct that can adjust dynamically to changes in air pressure. The two types of bypass dampers are mechanical barometric and static pressure electric control. Bypass duct and bypass damper installation guidelines 1.
Determine the correct size of the bypass duct needed based on the capacity of the system. Refer to Appendix C for Duct Sizing guidance.
2.
Select and install a bypass damper that is sized to fit the bypass duct. Install and calibrate the damper (Refer to Appendix C: Duct Sizing, page 39).
2.7 Zone Damper Wiring SmartZonePLUS™ will work with power close/spring open (2-wire) or power open/power close (3-wire) dampers.
Mixing 2-wire and 3-wire dampers are also acceptable (Refer to Figure
2.70). Each zone damper connection can support up to 13 three-wire dampers or four 2-wire dampers, or a mix of dampers up to 40VA per damper connection. The VA rating of the 24V transformer powering each SmartZonePLUS™ module must be sized to handle the total VA requirements.
Refer to Appendix B on Transformer Sizing Worksheet for additional
information. Install all zone dampers into the supply air ductwork for all zones.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 16
Number of Dampers per Zone Connector 2- wire damper
3- wire damper
(10VA per damper)
(3VA per damper)
Total Dampers
Total VA
4
0
4
40
3
1
4
33
3
2
5
36
3
3
6
39
2
4
6
32
2
5
7
35
2
6
8
38
2
7
9
34
1
8
9
34
1
9
10
37
1
10
11
40
0
11
11
33
0
12
12
36
0
13
13
39
Power Close/Spring Close/Spring Open (two(two-wire) Dampers Using minimum 18/2 or solid core wire, connect the PO (power open) and COM (common) connectors on the zone terminal block corresponding to the thermostat connector on each SmartZonePLUS™ board, to the same or equivalent connectors on the damper. (Thermostat 1 controls Damper 1, Thermostat 2 controls Damper 2, etc.) Power Open/Power Close (three(three-wire) Dampers Dampers Using minimum 18/3 solid core wire, connect the PO (power open), PC (power close) and COM (common) connectors on the zone terminal block corresponding to the thermostat connector on each SmartZonePLUS™ board, to the same or equivalent connectors on the damper. (Thermostat 1 controls Damper 1, Thermostat 2 controls Damper 2,…etc.)
Figure 2.70 – 2-wire and 3-wire damper wiring
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 17
2.8 Fresh Air Damper Wiring (optional) The Fresh Air Damper feature is an option in SmartZonePLUS™ and requires a fresh air duct system to be installed into the return air side of the duct system.
SmartZonePLUS™ is
compatible with 2-wire (power close/spring open), 2-wire (power open/spring close) or 3-wire (power open/power close) dampers.
2.9 Power On Test Before performing a power on test you should review steps 1 – 7 for correct completion. Also, double check 24V power wiring to verify polarity has been maintained from the transformer to all SmartZonePLUS™ boards. Review the communication wiring to insure COMM wire to “1”, “2” and “GND” are not crossed anywhere. Correct any wiring issues before proceeding. 1. Connect 24VA and 24V(c) from the transformer to the EC1 Controller PWR(IN) terminal block. The display panel should instantly display the firmware version “c3” or similar code for several seconds. 2. The following “Conditions” should appear on the EC1 and/or RZ1/RZ4 Expander boards connected to the EC1:
Component Location
Indicator
Condition
Module
Display Panel
(3 digit display)
Temperature is displayed
EC1 only
Display Panel
SA TEMP
Alternates display with OA
EC1 only
Display Panel
OA TEMP
Alternates display with SA
TEMP in 5 second interval EC1 only
TEMP in 5 second interval ‘R’ thermostat
‘R’ LED Indicator
Illuminated – Red
EC1, RZ1, RZ4
connectors
Lights
PWR(IN) & PWR(OUT)
LED Indicator Lights
Illuminated Green
EC1, RZ1, RZ4
LED Indicator Lights
Illuminated Green – “Open”
EC1, RZ1, RZ4
connectors Damper connectors
Illuminated Red – “Closed” COMM & COMM(IN)
LED Indicator Lights
Illuminated Blue
EC1, RZ1, RZ4
LED Indicator Lights
Illuminated Green – “Open”
EC1 only
connectors Fresh Air connector
Illuminated Red – “Closed” ‘W2’ or ‘O/B’ thermostat
LED Indicator
connectors
Lights*
Display Panel
*
Illuminated Orange
EC1,RZ1,RZ4
COMM LINK or
Illuminated Blue
EC1, RZ1, RZ4
COMM SEARCH
Illuminated Red
RZ1,RZ4
Applies only when “STAT TYPE SELECT’ button is set to ‘ON-Heat Pump’
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 18
2.10 Configuration 1. Configure each SmartZonePLUS™ board for the type of thermostat connected to it. Note: All SmartZonePLUS™ modules must be powered during this configuration step. Set the thermostat type for each SmartZonePLUS™ board by pressing STAT TYPE SELECT button for approximately 2 seconds. The LED indicator light to the left of the button will illuminate orange when ON for heat pump thermostats and will not be illuminated or OFF for gas/electric thermostats. Note:
When the EC1 Controller dipswitch dipswitch #1 is set to GAS/ELECT, GAS/ELECT, the ‘heat pump’
thermostat thermostat type selection option is not available on the EC1. The RZ1 and RZ4 Expanders offer ‘gas/electric’ or ‘heat pump’ thermostat type selections regardless of the EC1 dipswitch #1 setting.
Figure 2.10.1 – Thermostat configuration button 2. Configure the EC1 Controller dipswitch panel for the HVAC equipment Use the following table to find the HVAC equipment that matches your installation and adjust the EC1 Controller dipswitch panel to match the table settings. ECEC-1 Controller Dipswitch Configuration settings by HVAC Equipment Type HVAC
Dipswitch
Dipswitch
Dipswitch
Dipswitch
Equipment
#1
#2
#3
#8
GAS/ELEC
N/A
NORMAL
FAN
Gas/Electric Electric heat Gas/Electric
ELECTRIC GAS/ELEC
N/A
NORMAL
Gas heat Heat Pump
GAS HEAT PUMP
Aux dual fuel Heat Pump Aux elect heat
XCI Controls, L.P.
FAN
HEAT PUMP
SEE
DUAL
FAN
NOTE 1
FUEL
GAS
SEE
NORMAL
FAN
NOTE 1
December 19, 2008
ELECTRIC
P/N 220211-02
pg. 19
Note: Note: The REV VALVE O setting (factory default) energizes the reversing valve in cooling mode. This setting works with the majority of heat pump systems.
For those heat
pump systems that energize the reversing valve in heating mode set Dipswitch #2 to B. 3. Configure communications between the SmartZonePLUS™ EC1 Controller and RZ1/RZ4 Expander modules. Note: All SmartZonePLUS™ modules must be powered during this configuration step. a. For each RZ1/RZ4 Expander module that displays COMM SEARCH on its’ display panel, press and release the SET TYPE SELECT button (located immediately below the display panel) and within a few seconds COMM SEARCH should turn off and COMM LINK should display for that module.
Repeat this step for each RZ1/RZ4 module.
Check the
communication wiring to verify connections are correct and firmly attached to the connectors. Repeat this step if wiring adjustments are made and COMM SEARCH is still displayed. Warning!!! Perform the next step on any RZ1/RZ4 Expander module only if COMM LINK will not display after completing ‘step a’. b.
Perform this step only on those RZ1/RZ4 Expander modules that continue displaying COMM SEARCH after completing ‘step a’ above. 1) While pressing and holding down the STAT TYPE SELECT button, press and release the Reset button near the right margin of the XCI CONTROLS logo on the RZ1/RZ4 module. Within 2 seconds after releasing the second button the display panel will illuminate all display functions. 2) Continue holding down the STAT TYPE SELECT button for approximately 15 seconds until the display panel turns off and quickly redisplays all functions. Release the STAT TYPE SELECT button. 3) Within a few seconds the COMM LINK indicator should display. 4) If the COMM LINK indicator does not display, contact Technical Support at 866-9242875.
2.11 HVAC Equipment Wiring Solid core 18AWG wire is recommended for wiring connections in this step. Using the HVAC Equipment Wiring Table, connect the EC1 EQUIPMENT terminal block connectors to the HVAC equipment connections corresponding to the type of equipment used (gas/electric or heat pump). Note: SmartZonePLUS™ is equipped with a jumper attached to two pins next to the RH and RC terminals on the Equipment terminal block. This allows a single transformer to power both the ‘Rc’ Rc’ (24VAC power for cooling) and the ‘Rh’ Rh’ (24VAC power for heating) circuits. Remove this jumper when when using a transformer for a heating system that is separate from the transformer baseboard oard heat, or a fan used for the indoor blower, such as a radiant floor heat, radiant baseb powered box. The jumper must be disconnected disconnected so the transformers are not connected to the same terminal at the same time.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 20
Heat Pump
Function Description
Gas/Electric
From EC1
Typical
From EC1
Typical
or RZ
Heat Pump
or RZ
Gas/Electric
Expander
Thermostat
Expander
Thermostat
Thermostat
Connections
Thermostat
Connections
Connectors 24V power
Connectors
24V
24V
24V
24V
24V common
24V(c)
24V(c)
24V(c)
24V(c)
Compressor Stage 1
Y or Y1
Y or Y1
Y or Y1
Y or Y1
Compressor Stage 2
Y2
Y2
Y2
Y2
Fan control
G
G
G
G
Furnace Stage 1
-
-
W or W1
W or W1
W or W1
W or W1
-
-
Emergency Heat
EH
EH
-
-
Furnace Stage 2
-
-
W2
W2
Reversing Valve
O/B
O/B
-
-
H
Refer to
H
Refer to
G2
Section 2.12
G2
Section 2.12
Aux heat
O or B Humidity Control Multispeed fan
2.12 Optional Configuration Settings Settings High and Low Temp Cutout - While operating in heat or cool mode SmartZonePLUS™ Electronic Limit Control (ELC) monitors supply air temperature in the plenum. ELC will de-energize calls to the compressor equipment when temperatures in the plenum fall below the preset low temperature cutout. If the high temperature cutout is exceeded ELC will de-energize the calls to the furnace. A variety of factors such as geographical location and type of HVAC equipment may require some tuning of the high and low temperature cutout settings to optimize the HVAC equipment’s operation.
The following table illustrates the factory default settings and
adjustment parameters for high and low temperature cutouts. High and Low Temperature Cutout Parameters Cutout Control Low Temperature Cutout High Temperature Cutout
Factory
Adjustment
Default
Parameters
48O
F
41O – 52O F
Gas heat
135O F
90O – 150O F
Heat Pump
120O F
110O – 125O F
Dual Fuel* 120O/135O F
90O – 150O F*
* 1st stage default cutout is 120O F, 2nd stage default cutout is 135O F. XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 21
1. On the EC1 Controller repeatedly press the SET/NEXT button to continue cycling through the display panel functions until the HI TEMP or LO TEMP lights are illuminated on the display panel.
The
corresponding default cutout temperature will be displayed
simultaneously as HI or LO TEMP is displayed. Note:
SmartZonePLUS™ will return the EC1 display to normal operating mode when 5
seconds elapse after pressing a display control button. 2. Within 5 seconds adjust the cutout temperature by pressing the UP or DOWN arrows until the preferred temperature cutout setting is displayed. 3. Press the SET/NEXT button to save the new setting 4. Verify the change was accepted by repeating step 1 to display the revised cutout temperature. Fresh Fresh Air Timer - The fresh air timer is displayed in minutes per hour of fan run time that the fresh air damper will be open. The timer is adjustable in 5 minutes increments within a range of 0 – 60 minutes. For example, a fresh air timer setting of 5 minutes means the fresh air damper will be open for first 5 minutes each hour during fan run time. NOTE: If NO fresh air damper is installed, ‘0’ minutes must be set or the equipment fan will run unnecessarily. 1. Repeatedly press the SET/NEXT button on the EC1 Controller until FA TIMER is displayed on the display panel. 2. Within 5 seconds adjust the cutout temperature by pressing the UP or DOWN arrows until the preferred fresh air timer setting is displayed. 3. Press the SET/NEXT button to save the new setting Humidity Humidity Control SmartZonePLUS™ factory defaults to the dehumidify (dH) setting. Humidity Control requires the use of a humidistat on Zone 1 of the EC1 Controller. A humidistat is not needed if only dehumidification (DE HUM) is required.
To activate the SmartZonePLUS™ Humidity Control,
dipswitch #7 on the EC1 Controller must be set to the HUM/DE HUM position. Configuring Humidification – When configured for humidification, SmartZonePLUS™ will energize the G2 H equipment circuit when the EC1 registers an active heating call to the equipment from any zone thermostat, and ‘H’ must be energized on the Zone 1 thermostat. 1. Set dipswitch #7 on the EC1 Controller to the HUM/DEHUM position. 2. Press the SET/NEXT button repeatedly on the EC1 Controller until the orange ‘DE HUM’ indicator appears on the display. The EC1 display should display ‘dH’ as the dehumidify factory default setting. 3. Change the setting to the ‘H’, or humidify setting by pressing the up or down arrow button until ‘H’ is displayed. 4. Press the SET/NEXT button to save the new setting. Configuring Dehumidification – When configured for dehumidification, SmartZonePLUS™ will de-energize the G2 H equipment circuit when no calls are energized in the system except the
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 22
EC1 Zone 1 thermostat.
‘DH’ on the Zone 1 thermostat must also be de-energized.
To
configure dehumidification, follow the steps listed above for Configuring Humidification except change the setting to ‘dH’ MultiMulti-speed fan The G2 terminal on the EC1 Controller Equipment terminal block is used with a variable-speed fan.
Connect the DS, BK, ODD or DHUM terminal on the HVAC equipment to this terminal.
When 20% or greater of the total zones are calling for the same mode that is currently energized, G2 will be energized. This applies to HEAT, COOL and FAN modes. To activate this feature set dipswitch #7 on the EC1 Controller to the left, or G2 position. Economy Economy/Comfort Mode The SmartZonePLUS™ Economy/Comfort Mode feature can reduce HVAC equipment run time compared to the default individual zone control operation.
This is accomplished by limiting
one or more selected thermostats to making cool/heat calls to the equipment while the remaining thermostats are restricted from making calls to the equipment. SmartZonePLUS™ will monitor the equipment mode and open the dampers for those restricted zone thermostats calling for the same mode the equipment is satisfying. SmartZonePLUS™ provides three levels of ECONOMY/COMFORT MODE control. System Economy Control - At this level of Economy/Comfort Mode, only the EC1 Zone 1 thermostat can energize heating and cooling calls to the equipment. All other zone(s) making a call for the same mode that is also energized on the EC1 Zone 1 thermostat will open their damper(s). Each zone will close its damper(s) when the zone thermostat is satisfied. All zone dampers will open when all zone thermostats are satisfied.
Economy/Comfort Mode at the
System Control level can be activated by connecting a jumper wire to the CE IN and 24V connectors on the EC1 Controller ECON terminal block. Expander Board Economy/Comfort Economy/Comfort Control - With this Economy/Comfort Mode, all zones on selected RZ1 and/or RZ4 Zone Expander boards can be configured for Economy Mode. Zones on RZ1/RZ4 boards configured for this level of economy control will open their damper(s) when making a call for the same mode that is also energized on the HVAC equipment. Each zone will close its damper(s) when its zone thermostat is satisfied. All zone dampers will open when the current HVAC equipment mode de-energizes. This level of Economy Mode is configured by installing a jumper block over the two pins labeled ‘zone permanent economy mode’ for the RZ1, or ‘all zone permanent economy mode’ for the RZ4. These jumper pins can be found near the upper right corner of the display panel on the Zone Expander boards. Zone Thermostat Economy/Comfort Economy/Comfort Control - Selected individual zones can be restricted from making direct calls to the HVAC equipment yet open their damper(s) if making a call for the same mode that is also energized on the equipment. Each zone configured for this economy mode will close its damper(s) when its zone thermostat is satisfied. All zone dampers will open when the current HVAC equipment mode de-energizes.
Economy/Comfort Mode can be
configured for an individual zone (except for the EC1 Controller Zone 1) by connecting a switch,
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December 19, 2008
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pg. 23
such as a timer or motion detection, or infrared sensing switch to indicate occupancy in that zone. Connect ‘R’ and ‘EC’ connectors through the switch to put the corresponding zone into economy mode from the zone thermostat terminal block. Opposing Heat and and Cool Calls Calls Dipswitch #6 on the EC1 Controller is set to the left or default position. The default setting configures the EC1 to determine the changeover timing interval which will vary from 5 minutes to 25 minutes. SmartZonePLUS™ can be configured to use a 15 minute fixed change over time interval by setting dipswitch #6 to the FIXED TIME position. Refer to Section 3.4 for further
information. HVAC Equipment Staging SmartZonePLUS™ will use time and temperature to control staging automatically negating the need to use more expensive multi-stage thermostats. Refer to Section 3.1 Staging Control for
information describing the SmartZonePLUS™ staging processes. Dipswitch #5 on the EC1 Controller will be set to ‘2nd STAGE’ by default from the factory to enable the SmartZonePLUS™ automatic staging feature called Electronic Limit Control (ELC). Using Zone 1 Staging Control – The EC1 Zone 1 thermostat terminal will accommodate 2nd stage cool (Y2) and heat (W2) wiring connections to a multi-stage thermostat. It is only necessary to use these 2nd stage connectors if using a thermostat to control staging. In this configuration, the EC1 Zone 1 thermostat has priority for staging control over SmartZonePLUS™.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 24
Section 3: SmartZonePLUS™ Control Functions 3.1 Staging Control
Gas/Electric Equipment Staging Processes HVAC
Initial Run
Mode
Time
Action Description/> Notes
Thermostat
Equipment
Display
LED
LED
Panel
Y,G
Y1, G, H G2
COOL
Y,G
Y1,Y2,G,H
COOL
Cooling 1st
stage
8 minutes
Energizes equipment cooling mode from any zone thermostat calling for cool fan call for high speed DeDe-energizes 1st stage when thermostat satisfied
2nd stage
After 1st
Energizes after 1st stage initial run time if
stage initial
supply air temp > 10F above LO TEMP cutout
run time (8
DeDe-energizes 2nd stage if supply air temp < 4F
minutes)
above LO TEMP cutout
G2
3 minute compressor short cycle lockout timer activated after de-energizing 2nd stage
Heating 1st stage
8 minutes
Energizes equipment heating mode from any
G,W1 EH
G,W1 EH
HEAT
G,W1 EH
G, W1 EH,
HEAT
zone thermostat calling for heat DeDe-energizes 1st stage when thermostat satisfied 2nd stage
After 1st
Energizes after 1st stage initial run time if
stage initial
supply air temp < 25F below HI TEMP cutout
run time (8
DeDe-energizes energizes after 2nd stage initial run time if
minutes)
supply air temp > 10F below HI TEMP cutout
XCI Controls, L.P.
December 19, 2008
W2 O/B
P/N 220211-02
pg. 25
Heat Pump Equipment Staging Processes HVAC
Initial
Mode
Run Time
Action Description/> Notes
Thermostat
Equipment
Display
LED
LED
Panel
Y,G,W2 O/B* *
Y1,G,H G2,
COOL
Cooling 1st
stage
8 minutes
Energizes equipment cooling mode from any
W2 O/B
zone thermostat calling for cool EC1 dipswitch #2 OFF – if set to ON equipment W2 O/B LED will be OFF fan call for high speed DeDe-energizes 1st stage when thermostat satisfied 2nd stage
Energizes after 1st stage initial run time if supply
Y,G,W2 O/B* *
Y1,Y2,G,H
COOL
G2, W2 O/B
air temp > 10F above LO TEMP cutout EC1 dipswitch #2 OFF – if set to ON equipment W2 O/B LED will be OFF DeDe-energizes 2nd stage if supply air temp < 4F above LO TEMP cutout 3 minute compressor short cycle lockout timer activated after de-energizing 2nd stage
Heating 1st stage
4 minutes
Energizes equipment heating mode from any
Y,G
Y1,G
HEAT
Y,G
Y1,Y2,G
HEAT
Y,G
Y1,Y2,G,W1
HEAT
G,W1 EH
G,W1 EH
EH
zone thermostat calling for heat DeDe-energizes 1st stage when thermostat satisfied 2nd stage
3 minutes
Energizes after 1st stage initial run time if supply air temp < 15F below HI TEMP cutout DeDe-energizes after 2nd stage initial run time if supply air temp > 5F below HI TEMP cutout
Aux Heat
Energizes after 6 minutes continuous heating in 1st
and/or
2nd
stage and supply air temp < 90F
DeDe-energizes after supply air temp is > 100F Emergency
Emergency Heat call can be made only by
Heat†
manual control from Zone1 thermostat connected to EC1 Controller Depending on thermostat, Emergency Heat is dede-energized by satisfying the thermostat setpoint or exceeding the HI TEMP cutoff
An opposing call must be made by Zone 1 after the Emergency Heat call is satisfied before calls from remaining zones can be acknowledged and processed
*
the W2 O/B Thermostat LED will not be illuminated if a gas/electric thermostat is used
†
Emergency Heat can be activated only when switched on manually from the Zone 1 thermostat connected to the EC1 Controller – heat pump thermostat is required
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 26
3.2 Heat Pump Reversing Valve Control SmartZonePLUS™ can be configured to energize the heat pump reversing valve for cool or heat mode using dipswitch #2 on the EC1 Controller. The default setting has dipswitch #2 set to REV VALVE O which energizes the reversing valve in cool mode.
For HVAC equipment that
energizes the reversing valve for heat set dipswitch #2 to the right or B.
3.3 Heat Pump Balance Point Control The heat pump balance point control feature provides adjustable temperature settings that will restrict the compressor and auxiliary heat from energizing based on outdoor temperatures. The outdoor temperature sensor connects to the EC1 Controller ‘OA SENSOR’ terminal block. Note: This feature requires installation of the optional outdoor temperature sensor and setting dipswitch #1 on the EC1 Controller to the ON or HEAT PUMP position. Balance Point LO TEMP Cutout (factory default = OFF) - The balance point LO TEMP cutout prevents the compressor from operating if the outside temperature falls below the LO TEMP balance point cutout setting. The LO TEMP balance point cutout temperature can be adjusted from 1 – 40O F. Auxiliary heat will be energized or de-energized as heating calls are satisfied or made subject to time and temp staging controls for heat pump systems (See Heat Pump Equipment Staging Processes on p. 26). To change this setting press the SET NEXT button (11 times) on the EC1 Controller until the flashing LO TEMP and OA TEMP indicators both appear on the display panel. Press the UP or DOWN arrow buttons to adjust the setting to the desired temperature.
Press the SET NEXT button within five seconds to save the new setting.
Deactivate or turn off this control setting by pressing the UP or DOWN arrow button until ‘- -‘ appears on the display panel. Press the SET NEXT button within five seconds to save the new setting. Auxiliary Heat HI TEMP Cutout (factory default = OFF) - The Balance Point HI TEMP cutout prevents auxiliary heat from operating if the outside temperature exceeds the HI TEMP balance point cutout setting. The HI TEMP balance point cutout temperature can be adjusted from 40 – 140O F.
The heat pump compressor will continue to energize or de-energize as needed in
response to calls for heat. To change this setting press the SET NEXT button (12 times) on the EC1 Controller until the flashing HI TEMP and OA TEMP indicators both appear on the display panel. Press the UP or DOWN arrow buttons to adjust the setting to the desired temperature. Press the SET NEXT button within five seconds to save the new setting. Deactivate or turn off this control setting by pressing the UP or DOWN arrow button until ‘- -‘ appears on the display panel. Press the SET NEXT button within five seconds to save the new setting.
3.4 Opposing Heating and Cooling Calls Calls In the context of this manual “opposing calls” refers to the coexistence of heating and cooling calls from different thermostats attached to a single SmartZonePLUS™ system.
The typical
residential and light commercial system is unable to heat and cool at the same time so a method of managing opposing calls becomes necessary to determine what mode, heating or
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 27
cooling, receives priority and for how long. SmartZonePLUS™ offers two methods described below for managing opposing calls. Dynamic Opposing Call Management (factory default) - SmartZonePLUS™ defaults to managing opposing heating and cooling calls using a dynamically adjusted changeover timer based on the % of opposing calls to the total active calls registered on the SmartZonePLUS™ EC1 controller. SmartZonePLUS™ dynamically adjusts the changeover time because as new calls are received and existing calls are satisfied the % of active opposing calls changes. SmartZonePLUS™ is preconfigured to use the dynamic opposing call management method with dipswitch #6 on the EC1 Controller set to OPP CALL%.
The following table illustrates the rules used by
SmartZonePLUS™ to determine the changeover timing interval for opposing call percentages.
% of Active Opposing Call Zones
Opposing Call Changeover Time
Less than 20%
25 minutes
20% to 39%
20 minutes
40% to 60%
15 minutes
61% to 79%
10 minutes
80% or more
5 minutes
Fixed Time Opposing Call Management - SmartZonePLUS™ uses a 15 minute fixed interval for changeover if the fixed time opposing call method is selected. Set dipswitch #6 on the EC1 Controller to the FIXED TIME position to enable.
3.5 Emergency Heat Call – Heat Pumps Calls for emergency heat can be made only from a heat pump thermostat connected to Zone 1 of the EC1 Controller. Additionally, the heat pump equipment and EC1 Zone 1 thermostat both must have an emergency heat feature.
Section 4: SmartZonePLUS™ Operation & Monitoring 4.1 Using the EC1 Display Display Panel and Push Buttons The SmartZonePLUS™ display panel is a powerful and convenient tool for monitoring overall system status, adjusting control settings and troubleshooting. Control settings can be adjusted only at the EC1 Controller while the RZ1/RZ4 Expander modules include a subset of display panel functions to allow convenient monitoring of system operations when expanders are mounted remotely. Push Button Flow The push buttons are used for several different functions.
See descriptions below for
information on how to use the buttons to setup and view SmartZonePLUS™ Controller settings.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 28
Figure 4.0 – Push Button Controls Using the push buttons to set up desired options of the EC1 is very simple.
Pressing the
SET/NEXT (right) button starts the process, the UP and DOWN buttons allow adjustments of the options , and the CANCEL (left) button cancels the set up process and is used to select either G/E or HP thermostat for Zone 1. Below is an ordered list of each set up option. 1st Press: COOL ZONES CALLING (INFORMATIONAL ONLY) Press the SET/NEXT button and the display will change to a solid green COOL and a solid yellow ZONES, indicating the number of zones in the system currently calling for COOL. This number represents only the zones capable of initiating an equipment call (no zones in the ‘ECONOMY MODE’). 2nd Press: HEAT ZONES CALLING (INFORMATIONAL ONLY) Press the SET/NEXT button and the display will change to a solid red HEAT and a solid yellow ZONE, indicating the number of zones in the system currently calling for HEAT. This number represents only the zones capable of initiating an equipment call (no zones in the ‘ECONOMY MODE’). 3rd Press: TOTAL ZONES (INFORMATIONAL ONLY) Press the SET/NEXT button and ZONES will display indicating the total number of zones for the system. This number represents all zones in the system based on the number of thermostat connectors on all connected SmartZonePLUS™ boards. 4th Press: EQUIPMENT MODE CHANGEOVER TIMER (INFORMATIONAL ONLY) Press the SET/NEXT button and the display will change to a solid yellow CHG OVR indicating the minutes remaining before the equipment is to switch modes.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 29
5th Press: Electronic Limit ControlTM (ELC) – LO TEMP CUTOUT
Before setting the High and Low Temperature Equipment cutout Set Points, ensure that the DIP switches are set correctly choosing the proper equipment type. See ELC below for a full description. Press the SET/NEXT button and the LO TEMP cutout value will be displayed in Fahrenheit. A flashing green “LO TEMP” will also display. LOW Temperature Cut-Out (Factory Default - GAS/ELECTRIC = 48°F; HEAT PUMP = 48°F) 1. While the green “LO TEMP” indicator is flashing, within 15 seconds press either the UP or the DOWN arrow button to change the LOW Temperature cutout.
The temperature
indicated here represents the lowest temperature allowed at the supply air sensor. 2. Within 15 seconds after setting the LO TEMP cutout, press the SET/NEXT button to save the new setting and the display will proceed to the HI TEMP function. 6th Press: Electronic Limit ControlTM (ELC) – HI TEMP CUTOUT If the LO TEMP setting was not reset in the previous paragraph, press the SET/NEXT button and the HI TEMP cutout value will be displayed in Fahrenheit. A flashing red ‘HI TEMP” will also display. HIGH Temperature cutout (Factory Default - GAS/ELECTRIC = 135°F; HEAT PUMP = 120°F) 1. While the red “HI TEMP” indicator is flashing, within 15 seconds press either the UP or the DOWN arrow button to change the HIGH Temperature cutout.
The temperature
indicated here represents the highest temperature allowed at the supply air sensor. 2. Within 15 seconds after setting the HI TEMP cutout, press the SET/NEXT button to save the new setting and the display will proceed to the DE HUM function. 7th Press: DEHUMIDIFY/HUMIDIFY (dipswitch #7 must be set to DE/HUM to display this function) If the HI TEMP setting was not reset in the previous paragraph, press the SET/NEXT button and a solid orange DE HUM will display. The DE HUM setting will display as a solid green ‘dH’ (dehumidify) or ‘H’ (humidify). DEHUMIDIFY/HUMIDIFY settings (Factory Default – ‘dH’) 1. Change settings by pressing the UP or the DOWN arrow button to select DEHUMIDIFY (dH) or HUMIDIFY (H). 2. Within 15 seconds after selecting the settings required, press the SET/NEXT button to save the new setting and the display will proceed to the FA TIMER function. 8th Press: FRESH AIR TIMER 1. Press the SET/NEXT button and the display will change to a flashing green FA TIMER. The time is indicated in Number of Minutes-Per-Hour that the Fresh-Air Damper will be OPEN.
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December 19, 2008
P/N 220211-02
pg. 30
2. While the green “FA TIMER” indicator is flashing, within 15 seconds press either the UP or
the DOWN arrow
button
to
change to
the timer
to
the
desired
value.
NOTE: If NO Fresh Air Damper is installed,’0’ (Zero) Time must be set or the equipment fan will run unnecessarily. 3. After the desired FA TIMER time has been selected, press the SET/NEXT button to save the new FA TIMER setting and proceed to the FA LO TEMP function. 9th Press: FRESH AIR – LO TEMP CUTOUT (dipswitch #1 must be set to HEAT PUMP to display this function) function) NOTE: An outdoor temperature sensor must be connected to the EC1 Controller for this function to operate.
To set the High and Low Temperature FRESH AIR cutout settings follow the steps below, before completing these steps, ensure that an outdoor temperature sensor is connected to the EC1 Controller. Failure to install an outdoor temperature sensor will cause the Fresh Air temperature cutout settings to be ignored. Press the SET/NEXT button and flashing green FA LO TEMP will display including the current setting in Fahrenheit if changed previously. On initial startup factory default will be OFF and ‘ - - ‘ will be displayed. FA LO TEMP cutout (Factory Default – ‘- -‘ indicates FA temperature control is OFF) 1. While the green “FA LO TEMP” indicator is flashing, within 15 seconds press either the UP or the DOWN arrow button to change the FRESH AIR LOW Temperature cutout. The temperature indicated here represents the lowest outdoor temperature at which the fresh air damper will open to mix outside air into the return air plenum. 2. Within 15 seconds after setting the LO TEMP cutout, press the SET/NEXT button to save the new setting and the display will proceed to the FA HI TEMP function. 10th Press:
FRESH AIR – HI TEMP CUTOUT (dipswitch #1 must be set to HEAT PUMP to display
this function) NOTE: An outdoor temperature sensor must be connected to the EC1 Controller for this function to operate. Press the SET/NEXT button and flashing green FA HI TEMP will display including the current setting in Fahrenheit if changed previously. On initial startup factory default will be OFF and ‘ - - ‘ will be displayed. FA HI TEMP cutout (Factory Default – ‘- -‘ indicates FA temperature control is OFF) 1. While the red “FA HI TEMP” indicator is flashing, within 15 seconds press either the UP or the DOWN arrow button to change the FRESH AIR HIGH Temperature cutout.
The
temperature indicated here represents the highest outdoor temperature at which the fresh air damper will mix outside air into the supply air plenum.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 31
2. Within 15 seconds after setting the HI TEMP cutout, press the SET/NEXT button to save the new setting and the display will proceed to the LO TEMP balance point setting for heat pump. 11th Press:
HEAT PUMP BALANCE POINT – LO TEMP CUTOUT (dipswitch #1 must must be set to HEAT
PUMP to display this function) NOTE: An outdoor temperature sensor must be connected to the EC1 Controller for this function to operate. 1. While the “LO TEMP” and “OA TEMP” indicator is on, within 15 seconds press either the UP or the DOWN arrow button to change the low temperature at which the compressor will not operate in the heat pump heating mode. Only Auxiliary Heat (W1-EH) will be allowed to energize on a call for heat pump heating when the Outdoor Air temperature is below the cutout temperature. 2.
Within 15 seconds after setting the LO TEMP cutout, press the SET/NEXT button to save the new setting and the display will proceed to the HI TEMP balance point setting for heat pump.
12th Press:
HEAT PUMP BALANCE POINT – HI TEMP CUTOUT (dipswitch #1 must be set to HEAT
PUMP to display this function) NOTE: An outdoor temperature sensor must be connected to the EC1 Controller for this function to operate. 1. While the “HI TEMP” and “OA TEMP” indicator is on, within 15 seconds press either the UP or the DOWN arrow button to change the high temperature at which the Auxiliary Heat (W1-EH) will not operate in the heat pump heating mode. Only the compressor will furnish heat in the heat pump heating mode when the Outdoor Air temperature is above the balance point high temperature cutout. 2. Within 15 seconds after setting the BALANCE POINT HI TEMP cutout, press the SET/NEXT button to save the new setting and the display will go the the normal operation. 13th Press: NORMAL DISPLAY (INFORMATIONAL (INFORMATIONAL ONLY) Press the SET/NEXT button and display will return to normal operation.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 32
4.2 Display Panel Indicators
NORMAL OPERATION
SETUP MENU
Below the display indicators an installer or user might see during normal operation are listed and described. For further detail, refer to the SmartZonePLUS™ System Manual SA TEMP
To start the setup process, press the right arrow button. The numbers in the column to the left indicate the # of button presses needed to see the setting indicated below. All settings can be adjusted with the up and down pushbuttons. ZONES + COOL
Right Button Press 1
Temperature displayed by EC1 is the Supply Air Temp
Number of Zones calling for Cool mode displayed by EC1
2
OA TEMP Temperature displayed by EC1 is the Outdoor Air Temp (if “--“ displayed then NO outdoor sensor installed)
Number of Zones calling for Heat mode displayed by EC1
3
COMM LINK Communications Link established with at least one RZ1 or RZ4
ZONES Total Number of Zones connected and communicating to EC1
4
HEAT
ZONES + HEAT
CHG OVR Time in minutes before system will begin PURGE to switch modes (“--“ will be displayed if no calls present)
System is running in Heat mode
5
COOL System is running in Cool mode
LO TEMP (FLASHING) Low Temperature Limit displayed by EC1
6
EH System is running in Emergency Heat mode (only for Heat Pump and only if Zone 1 Thermostat is calling for Emer.Heat)
High Temperature Limit displayed by EC1
7
DELAY System is on 3 minute time delay because all calls have been satisfied
DE HUM or HUM Humidification or DeHumidification Mode can be selected by pressing the up or down pushbuttons
8
PURGE + HEAT
HI TEMP (FLASHING)
FA TIMER (FLASHING)
The system is purging from Heat mode and will start-up in Cool mode after 3 minutes
Time (Minutes per Hour) the Fresh Air Damper will be opened (Must be set to zero “0” if no Fresh Air Damper installed)
PURGE + COOL
FA TIMER + OA TEMP + LO TEMP
The system is purging from Cool mode and will start-up in Heat mode after 3 minutes
Low Outdoor Temperature Limit to prevent FA Damper from opening when Outdoor Temp is below this setting (will be ignored when no OA Sensor installed)
9
DE HUM or HUM The system is running in DeHumidification or Humidification mode (only if Zone 1 Thermostat is calling)
10
HI TEMP The system has cut-out on a High Temp Limit at the Supply Air Sensor (Equipment fan should still be running and system will start back up after 3 minute time delay and Supply Temp has dropped within range)
The system has cut-out on a Low Temp Limit at the Supply Air Sensor (Equipment fan should still be running and system will start back up after 3 minute time delay and Supply Temp has risen within range)
FA TIMER
OA TEMP + LO TEMP Low Balance Point Setting – On Heat Pump equipment this setting prevents the compressor from running below this set outdoor temperature
11
LO TEMP
FA TIMER + OA TEMP + HI TEMP High Outdoor Temperature Limit to prevent FA Damper from opening when Outdoor Temp is above this setting (will be ignored when no OA Sensor installed)
OA TEMP + HI TEMP High Balance Point Setting – On Heat Pump equipment this setting prevents the auxiliary heat from running above this set outdoor temperature
12
Fresh Air Damper is open
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 33
Appendix A: EC1 Controller Dipswitch Dipswitch Settings
DIP #1
DIP #2
DIP #3
DIP #4
GAS/ELECT
Gas/Electric or Electric/Electric equipment (factory default)
HEAT PUMP
Heat pump using electric auxiliary or emergency heat
REV VALVE O B NORMAL
DIP #6
DIP #7
DIP #8
Reversing valve is energized in HEATING Gas/Electric, Electric/Electric or Heat Pump using electric auxiliary or emergency heat
DUAL FUEL
Heat pump using fossil fuel auxiliary or emergency heat
MODE ALL
Normal Opposing Call Changeover is active. (factory default)
Z1 PRIORITY 2ND STAGE
DIP #5
Reversing valve is energized in COOLING (factory default)
20%+ZONE1
Opposing Call is Locked Out until Zone 1 is satisfied. Normal Operation – 2nd stage is always active (factory default) 2nd Stage energized using ELC with minimum of 20% of zones calling, or Zone 1 can initiate 2nd Stage.
OPP CALL %
Dynamic opposing call control activated (factory default)
FIXED TIME
15 minute delay between opposing calls
G2 HUM/DE HUM FAN GAS FAN ELECTRIC
XCI Controls, L.P.
Multi-speed fan control active (factory default) Humidify/Dehumidify controls active Gas heat (factory default) Electric heat
December 19, 2008
P/N 220211-02
pg. 34
Appendix B: Transformer and Fuse Sizing Worksheet Instructions: 1. List each SmartZonePLUS™ board used and the quantity of 2 and 3-wire dampers on each. 2. For each ‘board’ write in the minimum VA required (EC1 – 14VA, RZ1 – 10VA, RZ4 – 14VA) in column A. 3. For each 'board' write in the quantity of thermostats, 2-wire and 3-wire dampers to be used with each board. (Up to 4 dampers can be powered from each zone damper connector) 4. Multiply the ‘Quantity’ and ‘Total VA’ for thermostats, 2-wire and 3-wire dampers for each board and write the result in for each. 5. For each board add Columns A, B, C and D, and write the total in Column E.
Note: Each system must have one EC1 and can not exceed 33 zones total. Refer to Section 2.3 Power & Power wiring for information on using single or multiple transformers. Column
Column
Column
Column
A
B
C
D
SmartZone+
Thermostats
Boards
3-wire dampers
2-wire dampers
Column
E Minimum
Board
Total VA
Qty
VA
Total
each
VA
Qty
VA
Total
each
VA
Qty
VA
Total
VA
each
VA
for each board
EC1
14
3
3
10
RZ1
10
3
3
10
RZ4
14
3
3
10
3
3
10
3
3
10
3
3
10
3
3
10
3
3
10
3
3
10
3
3
10
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 35
Transformer Sizing Example: SmartZonePLUS™ System with 7 zones 1
EC1 Controller
2 2-wire dampers
1
RZ4 Expander
4 3-wire dampers
1
RZ1 Expander
2 3-wire dampers
1
RZ1 Expander
1 2-wire dampers
SmartZone+
Thermostats
Boards Board
Total VA
Qty
3-wire dampers
VA
Total
each each
VA
EC1
14
1
3
3
RZ1
10
1
3
3
RZ1
10
1
3
3
RZ4
14
4
3
12
NOTE:
Qty
VA
Total
each
VA
3 2
3
3
Qt y 2
6
3 4
2-wire dampers VA
Total
Minimum VA for
each
VA
each board
10
20
37 19
10 1
12
10
10
10
23 38
Thermostat VA ratings used in the sizing worksheet are based on XCI Controls TrueTouch thermostats.
Other brand thermostats may have different VA
requirements. Transformer Sizing Options for Example Above: Option 1: Use two 75VA transformers – one for the EC1 and an RZ1, one for the RZ4 and an RZ1 Option 2: Use a single 100VA transformer to power all boards
Transformer Fuse Sizing Table Transformer Size
Maximum Recommended
(Voltage Amps)
Fuse Size (Amps)
20VA
1A
40VA
2A
75VA
4A
100VA
6A
150VA
8A
NOTE: Exceeding maximum fuse size risks damage to electrical electrical components.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 36
Appendix C: C: The Duct System
Figure 3: SmartZonePLUS™ Bypass Duct System Overview
SmartZonePLUS™ will often furnish conditioned air to only part of the whole area that is serviced by the heating and cooling system. Yet, most residential HVAC equipment is designed to operate at full capacity or be turned off. When all zones are open the system will operate normally, but when a few dampers are open it is critical that the zoning system relieve the excess air pressure back into the return air plenum. This is accomplished with a bypass duct and an adjustable bypass damper. THE BYPASS DAMPER IS DESIGNED TO MAINTAIN A REASONABLY CONSTANT SUPPLY DUCT PRESSURE AS ZONE DAMPERS OPEN AND CLOSE. Temperature in the supply duct will be affected as more or less supply air is bypassed into the return air plenum. allowed to get too cold or too hot.
This supply air temperature cannot be
Included with the SmartZonePLUS™ EC1 controller is a
temperature sensor connected to the Electronic Limit Control (ELC). This function in the controller will break Y1 or W1 if the supply air temperature exceeds the heating or cooling cutout set points. The ELC will automatically allow Y1 or W1 to close after a minimum 3 minute time delay or when the supply temperature has recovered within the cutout limits.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 37
Bypass Duct Sizing The formula for sizing bypass dampers and ductwork is TOTAL CFM – CFM OF SMALLEST ZONE = CFM TO BE BYPASSED. USING A DUCT-U-LATOR, APPLY CFM TO BE BYPASSED AT 1500FPM TO FIND DUCT SIZE FOR BYPASS DAMPER. Note: A standard rule of thumb for sizing bypass in residential applications is: 5 tons = 14” round bypass damper 4 tons = 12” round bypass damper 3 tons and down = 10” round bypass damper Residential Load Calculation When sizing a supply duct system using zoning, XCI Controls recommends calculating a “whole house load calculation” as well as a “room-by-room load calculation”. The equipment should be sized based on the conditioning requirements of the “whole house” using maximum diversity. This simply means that the sun will never shine from the east and the west at the same time, all the occupants will not be in all the rooms at the same time, etc.
These are examples of items of
diversity that are automatically calculated into a load when maximum diversity is applied. Once the building’s Total Design CFM is established, choose HVAC equipment that will provide the Total Design CFM while also working within the static pressure requirements of the duct system of choice (flex duct, round metal, duct board, rectangular metal with exterior liner). Next, divide the Design CFM requirements for each zone by the total CFM available from the indoor equipment. Use Table
C1: Damper Sizing Chart below to select each damper that will accommodate the Zone Design CFM.
Residential Duct System On the other hand, room-by-room loads should be calculated with little or no diversity. No diversity means that using worst conditions, each zone should have a branch duct system designed to deliver the conditioned air necessary to satisfy the user-requested conditions. In low load conditions, each thermostat in each zone will reach setpoint and the zone damper will close, not allowing over conditioning.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 38
Figure 4: SmartZonePLUS™ Duct System – Branch Ducts Residential Supply Air Duct Sizing IMPORTANT: All air out of the blower must be routed through a supply air damper and ultimately through a supply defuser. Supply air ducts not routed through a damper will “dump” unwanted air into a space whenever the system is running whether the space is requesting the conditioned air or This is called a “dump zone” and is not recommended. (See Figure 4 above and Table C1
not.
below) 1. Once the total CFM of the HVAC system is determined, size the dampers using the “Design CFM” column on Table C1: Damper Sizing Chart below. A four ton HVAC system might be rated at 1600 CFM. If four zones are used the total CFM chosen for all four dampers should be approximately 1600 CFM. 2. Size each damper based on a percentage of the whole house load. If one zone requires 600 design CFM, choose a 12” damper. Dampers totaling approximately 1000 CFM still need to be selected. 3. Notice in Table C1 that the “Max Design CFM” for the 12” damper is 900.
This is the
maximum CFM that might move through the 12” damper if that damper is the only one open. Design the branch outlet duct system to accommodate Max Design CFM. This will insure that the system is quiet even when a single zone is receiving the maximum CFM when only one damper is open.
4.
To design the individual branches in the duct system, no more than 700 FPM face velocity at the
outlet
defuser
is
acceptable
in
order
to
provide
a
quiet
system.
EXAMPLE: Outlet size of 14” x 8”. Multiply 14 x 8 =112 sq. inches. Divide 112 by 144 (sq. inches in a sq. foot) to find .78 sq. ft. of opening. Multiply the maximum FPM of 700 moving through the duct into the opening size of .78 sq. ft. = 546 CFM. One last item must be
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 39
considered; most defuser charts will include a “free area multiplier”. This is simply the amount of air that will pass through the defuser uninterrupted by the diffuser’s restriction through the opening. If the free area multiplier is .80, multiply 546 CFM x .80 for the actual maximum design of 437 CFM. Since our branch CFM is 437, two 14” x 8” outlet defusers with 10” round inlets can be used to quietly deliver 900 CFM to a room at less than 700 FPM.
DAMPER SIZING CHART Damper Size 6” 7” 8” 9” 10” 12” 14” 16”
Design CFM 100 150 200 300 400 600 1000 1500
Max Design CFM 200 250 300 450 600 900 1400 2000
Example Wye 6X6X6 7X6X6 8X7X7 9X8X8 10 X 9 X 9 12 X 10 X 10 14 X 12 X 12 16 X 14 X 14
Table C1: Damper Sizing Chart Commercial Load Calculation Unlike residential load calculation, commercial load calculations must be calculated with minimum diversity in each area served by a specific air conditioning unit. This means that each HVAC unit should be designed to accommodate maximum capacity and usage during all times of the day. This strategy is most important during morning warm-up or cool down. Commercial buildings require a quick recovery, and SmartZonePLUS™ will furnish high quality part load control as well as better humidity control than standard DX HVAC systems without zone control. Commercial Duct System Commercial duct systems should also be designed using minimum diversity. Large occupancy loads can occur in a single zone during any time of the day or night so the ability to deliver the required CFM during peak load is essential. Commercial applications can require a greater static pressure in the supply duct so as to push more air greater distance. SmartZonePLUS™ is considered a “pressure dependent” system.
This means that the pressure
provided by the HVAC blower is the same general pressure that is maintained in the duct system if and when all zones are open. The bypass damper or VFD will be designed to maintain a constant duct pressure and pressure will be maintained approximately the same across the zone dampers when using SmartZonePLUS™. Engineers generally agree that a greater number of smaller HVAC units placed in similar load situations such as North, South, East or West exposures allow designers to use the heat placed in the unit instead of applying reheat in VAV boxes or fan powered boxes. This concept is less expensive first cost in structural design, electrical design as well as HVAC design. Cost of operation is easily less because this system never requires heating and cooling at the same time. Also, equipment blowers require less power to maintain a lesser duct pressure than
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 40
traditional pressure independent systems.
SmartZonePLUS™ will do a good job of controlling
individual space temperature when most of the zones are looking for the same mode. Excess Supply Plenum Pressure XCI Controls recommends any of four methods to control excess supply plenum pressure caused as supply dampers open and close.
The best method will be determined based on the specific
requirements of the application such as customer sensitivity to excess air noise, type of duct system used, actual duct design, ability to locate bypass duct in tight equipment location and installation cost. 1. No Bypass; Oversizing the duct system of a 2-zone system. 2. Barometric relief damper placed in the bypass duct from the supply plenum to the return air plenum. 3. Modulating power open/ power close bypass damper operated with a static pressure controller (SPC). 4. Variable Frequency Drive Blower Motor operated with a modulating static pressure controller. No Bypass When using two zones that are approximately the same size, it is acceptable to oversize the duct in each zone so that when only one of the two zones is open, all the air produced by the indoor blower is applied to the open zone. This requires calculating the duct size to deal with approximately twice the amount of air normally placed in the space. The duct sizing calculations should allow no more than 800 feet per minute of conditioned air at the terminal points (diffusers, registers and grills located in each zone).
This duct design has one advantage and several disadvantages.
The
advantage is that no bypass duct or damper is required; consequently the system’s operating temperature and pressure should be normal. One disadvantage is a very low duct pressure when both zones are calling. This means that the system’s ability to throw the air to the outside walls may be diminished. Another disadvantage is that when only one zone is calling, excess air in the calling zone tends to be drafty and conditions the calling zone too quickly, possibly over conditioning the space. Also, the larger than normal duct system is more expensive than a smaller duct system. Bypass Damper [And How it Works] A bypass duct is a short duct placed between the supply plenum and the return air plenum. The purpose of the bypass duct is to allow the excess pressure from the supply plenum to escape into the return air plenum. Excess pressure can occur in the supply plenum when less than all the zone dampers are open. This excess air must pass through a bypass damper that is mounted in the bypass duct. Excess pressure is restricted from freely flowing back to the return air plenum by adjusting the bypass damper. A bypass damper must be adjusted so that when all zones are open the bypass damper is closed, but lightly closed so that as supply dampers close and pressure mounts in the supply air plenum; this pressure pushes the bypass damper open. Excess pressure
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 41
escaping through the bypass damper is taken back into the return air system and re-circulated through the equipment.
Barometric Bypass A barometric relief damper is not motorized and houses a blade in the bypassed air stream attached to a shaft. The blade is opened as air pressure in the supply plenum builds and escapes through the bypass duct. As the damper blade opens the attached shaft rotates. The shaft extends outside the damper. There is a shaft collar with a ½ inch hole that slides over the end of the ½ inch shaft
(See Figure 5 below). A ¼ inch bolt that is 8 inches long screws through the side of the shaft collar and tightens onto the shaft. When weights are applied to this bolt, it is used as a weighted arm. The donut allows the weighted arm to be positioned at any location (360 degrees) on the shaft. By sliding the weight toward the end of the bolt, leverage is applied to the attached shaft, closing the blade in the bypassed air stream and adding restriction to the bypassed air flow. SetSet-Up and Adjusting a Barometric Bypass 1. Make certain that the arrow label on the barometric bypass damper is pointed in the direction of air flow; from the supply plenum toward the return air plenum. 2. Make certain that the shaft is located horizontally in the air stream and the blade is actually hanging down from the shaft inside the damper. This insures that the damper will swing open from the bottom and pivot from the shaft. 3. The barometric bypass damper shaft extends 3 inches on both sides of the damper. This allows room to insulate the bypass damper completely and still allow the weighted arm to pivot freely from the end of the shaft. 4. An eight inch long bolt with a ½” hex head is used as the weighted arm. Tighten the ½” hex head bolt that is threaded into a donut that slides over the end of the shaft. Loosen the bolt slightly to allow rotation of the donut on the shaft. This allows positioning of the weighted arm a full 360°. 5. Locate the weighted arm at approximately the 8:00 o’clock position or the 4:00 o’clock position depending on which direction the air is moving through the bypass damper. This weight should add restriction to the air moving past the blade inside the bypass damper. Retighten bolt onto the shaft and tighten the locking nut positioning the donut onto the shaft. 6. As the air pressure increases the blade inside the damper will be forced to pivot open which will turn the shaft. The weighted arm attached to the shaft should be lifted from it’s at rest position.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 42
7. The weight that slides up and down the 8” arm allows more or less leverage or weight to the arm. The weight includes an Allen screw so that an Allen wrench will tighten the weight after it is in position. Damper Blade
Shaft Collar Adjustable Weight
Correct Blade Position
Figure 5: SmartZonePLUS Barometric Bypass Damper
Modulating Bypass (Static Pressure Operated Bypass) Bypass) The static pressure operated bypass requires the use of a motorized power open/power close modulating damper.
As pressure increases in the supply plenum, the static pressure sensor will
register this increase and power the motorized damper open slowly so as to relieve the excess pressure. As the pressure is removed, the static pressure sensor may register less pressure in the supply plenum, consequently powering the bypass damper closed so as to make pressure.
This
constant hunting for the correct pressure requires a motorized damper that moves from open to close in approximately 45 seconds. In this application, no dead band is required. SetSet-Up and Adjusting a Modulating Bypass Damper with Static Pressure Controller 1. Power-open/Power-close damper can be mounted in any position in the bypass duct. 2. The static pressure controller (SPC) must be mounted so that the diaphragm is in the vertical position (See Figure 6 below). Use sheet metal screws to attach the feet of the SPC to the supply plenum within inches of the pitot tube. 3. The pitot tube should be inserted into the supply plenum between 2 and 4 feet from the beginning of the plenum. Insert the pitot tube perpendicular to air flow. The purpose of the tube is to measure AVERAGE supply air plenum pressure and report this pressure to the static pressure controller.
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 43
4. Attach the provided 12 inch rubber tube to the static pressure controller on the inlet barb labeled High-Pressure Inlet. Attach the other end of the 12 inch rubber tube to the pitot tube. 5. Wire the SPC, PO/PC Damper, included relay and a field supplied transformer as shown the included wiring instructions below (Figure 7) 6. Start the indoor blower in high speed and make certain all zones are open. 7. Using a flat head screw driver, turn the set screw on the SPC clockwise ¼ turn so that the motor continues to power the damper closed. If the damper reverses itself and starts to open, turn the set screw another ¼ turn clockwise until the bypass damper has closed and is remaining closed. 8. Slowly turn the set screw counter clockwise until the damper starts to open. Immediately reverse the motor by moving the set screw clockwise slightly so that the position is located where the damper is barely staying closed with all Zones OPEN. This becomes the setpoint for the static pressure controller. 9. As the supply dampers open and close the SPC will constantly hunt to maintain the static pressure that was established during the above start up procedure. 10. When all zones are satisfied and the indoor blower is de-energized, make certain that the bypass damper is powering open so that when it begins its next cycle, the bypass damper will start modulating from the OPEN position. If the relay is not wired correctly, the damper will close. On the next cycle with only one zone open, the bypass will start from the closed position and cause several seconds of excess air noise in the zone that is open. NOTE: See Next Page, Figures 6 & 7 for wiring and mounting information. For further
information about the Static Pressure Controller refer to the SPC Specification Sheet (separate document).
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 44
Wiring of Modulating Bypass Damper
Figure 6: Static Pressure Controlled Bypass Damper Installation
Figure 7: Static Pressure Controlled Bypass Damper Wiring Detail
XCI Controls, L.P.
December 19, 2008
P/N 220211-02
pg. 45
